EPC contract of Shahre-kord Cement Electrical, Control and Instrumentation Project

In this project, Fars Scott Industrial company has been responsible for detailed engineering, procurement, construction, commissioning, and starting up of all Electrical, Control and Instrumentation equipment in Shahrekord Cement Plant.

This project was handover June,2008. The most outstanding feature of this project was its location at the altitude of 2300 meters above sea level. At this altitude, selection and supply of higher power rating in electrical equipment was needed considering the reduction of the efficiency of electrical equipment.

Different tasks in this EPC contract is presented followed:

1: Engineering

All detailed engineering documents of whole Project in electrical, control, and instrumentation disciplines were provided by Fars Scout Industrial Co. The most important documents are listed below:

• Control documents including but not limited to:
• flow sheets, Signal Lists, I/O allocation, Cabinets Layout, Logic diagrams, and Alarm lists,

• control cable list and cabling layout,
• data communication networks,
• Controller programming and HMI design
• The control equipment specifications and data sheets.

• Instrumentation documents including but not limited to:

• Instrument list,
• Instrument cable list and cabling layout,
• Instruments specifications and data sheets.
• Instrumentation calibration and start up procedures.

• Electrical documents including but not limited to:

• HV station total design, 63KV, 30MVA, H type HV station
• HV station control interlocking, and protection design
• HV equipment specifications and data sheets.
• HV station civil design
• MV substation total design, 6.3KV, 30KA, double bus with coupling.
• MV substation single line design
• MV substation outgoing motor and transformer feeders design
• MV cable list and cabling layout
• MV cabinet layout design
• MV substation control interlocking, and protection design
• MV equipment specifications and data sheets.
• 400V substations total design in five different substations
• 400V substations single line design
• 400V substations distribution feeders design
• MCC feeders design
• 400V cable list and cabling layout
• 400V substations distribution and MCC cabinet layout design
• 400V substations and MCC protection design
• Emergency Auxiliary power design
• 400V Motor generator design
• 3phase UPSs for substations and control room design
• 400V substations equipment specifications and data sheets.

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  2 : Procurement

  All equipment needed for whole Project in electrical, control, and instrumentation disciplines were provided by Fars Scout Industrial Co. The most important procurement items are listed below:

• Control systems including but not limited to:
• Control system PLC cabinets provided by Siemens SIMATIC S7 – 400 | SIMATIC  Controllers  hardware  with  more than 5000 I/Os, making use of Siemens SIMATIC ET 200S distributed I/O modules.
• PCS7 Siemens Cement Process suit.
• Fiber Optic network between substations.
• ProfiBus and ModBus connection to subsystems.
• Marshalling cabinets.
• Workstations
• Supply MIS system Receiving production line information from control system and preparing management reports for production and technical management and providing the production data base and the consumables and maintenance data bases.

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• Instrumentation items procumbent including but not limited to:
• ABB Temperature, pressure, and transmitters
•  Siemens level measurement devices supplied for Cement industries
• position switches
• Schinke Vibration transmitters
• Voltage, current and power transmitters.
• ABB Pyrometers
• Kiln shell temperature monitoring system
• Delta Camera Kiln and cooler CCTV monitoring systems
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• Protection switches for screws, belt conveyers and elevators.
• Electrical items procurement including but not limited to:
• 63KV, 30MVA, H type HV station equipment.
• HV station control interlocking, and protection cabinets
• HV station Switches, HF6 Circuit Breakers,
• HV station CT and PT equipment
• HV station wall bushing and surge arresters.
• HV station steel structures
• HV station bus bars
•  MV substation, 6.3KV, 30KA, double bus coupling and incoming feeders, ABB 2500A vacuum VD4 circuit breakers.
• MV substation Bus Bar compartment.
• MV substation outgoing motor and transformer feeders, ABB 1600A & 1200A, VD4 vacuum circuit breakers.
• Withdrawable MV cabinet including Circuit Breakers, and Control and measuring Compartments.  
• 400V withdrawable distribution cabinets including ABB electrical components for all part of the factory
• MCC withdrawable distribution cabinets including ABB electrical components for all machineries of the factory in more than 110 cells
• Emergency Auxiliary distribution panels
• Supply 2 diesel generators device with total capacity of 1600 KVA
• Supply of 3phase UPSs for substations and control room with ratings of 10KVA, and 5 KVA, 6 Set
• Supply of ABB Motors and Drives for all consumers in the factory listed below:
• Supply of five ABB  MV Squirrel Cage Motors with dry starters from 1 MW to 4.6 MW from ABB Italy .
• Supply of 6 motors and variable speed drivers ( ABB, ACS800 Motor and Drives ) from ABB Finland with 6 and 12 phase Transformers up to 550 KW and one  Medium voltage  Motor and drive (ABB, ACS 1000 ) from ABB Switzerland with capacity of 2700 KVA and  3.3 KV voltage  rating with 12 phase transformers and solid state water cooling device for ID Fan.
• Supply of 55 ABB Low Voltage Motor from ABB Sweden with power ratings of 55KW to 250 KW that.
• Supply of ABB Motor soft starter for motors up to 100 KW.
• Supply all LV and MV capacitor banks including required inductance preventing the risk of resonant in the network considering the variable speed drive consumers.
• Supply X – Ray analyzer hardware and software for controlling the quality of device production from UK Oxford Company.

• 3 : Installation and Setting up

   Installation and commissioning of all control, instrumentation and electrical equipment, the most important of which are listed below

   

  - Installation, testing, commissioning, and startup of all 63 KW HV substation equipment and setting the protection relays.

  - Installation, testing, commissioning, and startup of all factory    transformers.

  - Installation, testing, commissioning, and startup of all MV substation 6.3 KV equipment and setting the protection relays.

  - Installation, testing, commissioning, and startup of 400V LV substation panels and setting the protection Relays.

  - Installation the tray and ladder in entire production line, underground tunnels, and substation basements.

  - Cabling of whole plant, including Medium Voltage and Low Voltage power cables, control and instrument and optical cables.

   

  - Installation, termination, testing, commissioning, and startup of all control system and programming of PLC controllers, and commissioning of Central Control Room computers.